1 - SAILTEC Custom Projects

sunDECK
All-weather sun shade systems for super yachts
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SAILTEC · Philosophy, Products, History.
We supply high quality system solutions for super yachts, architectural projects and the construction industry. SAILTEC systems
are optimized for the individual project, and made to order. Core products are
Sun Sails · Sun Roofs · Yacht Outfitting Systems · Lightweight Projection
Screens · Textile Architecture · Tensile Structures · Stainless Steel Rigging
Reliability, flexibility, innovative ideas, experience and continuity are cornerstones of our work, perfection is a motivating challenge. Our service includes design, load calculation, engineering, manufacture and installation – the complete turnkey package.
In 1984, we started to work for the yacht industry. Our first job for a yacht over 100 metres of length was an all-weather sun sail
in 1999, approved for 120 kn = 220 km/h of wind. The super yacht industry is a successful business area for SAILTEC. Presently, 10
of the world's 25 longest super yachts have SAILTEC systems on board.
Our tensile structures have proven to be attractive products for the architecture as well - serving as sun awnings, shading systems, or simply as stylish structural elements. Our first system for an architectural application was supplied in 1987.
Images
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A SAILTEC sun awning system, supplied in 2010 - MY PALLADIUM.
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SAILTEC’s first sun awning project ever, supplied in 1987 - RHÖN KLINIKUM.
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SAILTEC’s first sun awning project for a super yacht of over 100m length, supplied in 1999 - MY AL SALAMAH.
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sunDECK
sunDECK sun shades are tensile membrane structures, for weather and sun protection on large super yachts. They are designed
for permanent use, so they do not require to be taken off in any kind of weather. They are typically approved to withstand loads
of 100 knots = 185 km/h of wind. This is about 50% beyond force 12 on the Beaufort scale. They will stay in good shape even if
disposed to weather beyond hurricane force. sunDECK layout, construction and production are individually done to the order, and
to the technical and architectural / stylish wishes of our customer.
Our offer includes system responsibility and turn-key solutions:
Design and construction for the hole structure - this means membranes and carrying structure.
FEM load calculations for membrane and carrying structure,
Supply of carrying structures, membranes, hardware, and installation on board.
Component materials vary for the individual projects:
Carrying structures - Polished, brushed or blasted stainless steel, glass or carbon composites (painted or with woven carbon top
layer and varnished), sometimes mild steel or aluminium (galvanized, painted or powder coated).
Hardware and rigging components - Stainless steel, composite laminates, composite rigging.
Membranes - are made from weather-proof, UV-resistant, high-tech fabrics. Expected life span of sunDECK membranes lies between 10 and 25 years, depending on the individual conditions of use.
Pictures
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80m TALITHA, steaming down the river Elbe with her new SAILTEC sun shades.
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A 10mm stainless steel corner plate. Folded twice to follow the shape of the membrane exactly, and manually high-gloss
mirror polished. The tension wires and fork fittings are stainless as well, the fittings polished. Made for OCTOPUS in 2003.
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SAILTEC Textile Engineering.
SAILTEC sun shades are tensile membrane structures. The most important feature of a tensile structure is that it performs perfectly in all conditions of use. This is one of the important reasons for us to use high-tech software to design SAILTEC sun shades.
We invested into comprehensive textile engineering software for 3-D lightweight structure designs, which is being updated continuously.
The final membrane shape is the result of a process called Analytical Form-Finding. Analytical form finding is an instrument to
evaluate the geometry of a stressed surface. With our form finding software, a stress harmonic surface will be configured under
consideration of user-defined conditions.
To do this, we use Force Density. Our software calculates the optimum force density situation throughout the membrane, and
generates a Figure of Equilibrium for it. The ability to create a figure of equilibrium in combination with load case studies allows
us to analyse our membranes deeply. For various realistic load cases, we get exact data about the behaviour of the membrane.
Our software also allows us to configure individual load cases as required.
Images
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Load case printout of a 3-piece awning. This load case applied wind in a diagonal direction, in this case 60 degrees above
horizontal from the side of the ship, and you can see that the load vectors are different on portside and starboard. This is
a sunFLIP system for temporary use.
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Similar screen shot of a highly loaded membrane.
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A load case screenshot with very little stress on the membrane. This is a sunFLIP system as well.
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The key steps when designing a tensile membrane are:
The form finding process, this includes finding the optimum outer lines for the membrane.
Finding the optimum panel layout, make sure the panels are perfectly shaped, and their warp/ weft orientation is correct,
Make sure that there is no risk for water pockets on the membrane (in case of permanently used awnings a MUST, in case
of sunFLIP not always a requirement). We can test snow and/or ice loads as well - for ships visiting the arctic, this mostly
for permanent sun roofs.
Analyze wind load scenarios, and make sure the system components are strong enough to withstand the conditions it will
face during its life.
Study the membrane deflection under load, and make sure that potential elongation and deflection does not influence
the performance of the structure negatively.
Define the reaction loads for the supporting structures, and communicate these to the customer so he can make sure the
structure supports and basements are strong enough as well.
Images
The images above and below show a water drainage scenario for a permanently used sun awning (not a sunFLIP system). The
awning is shown from above, and is pictured showing a load case — wind load and a water column on the membrane (rain or
deck washing!) - a realistic situation.
The small gray arrows indicate the water flow. The length of the arrows shows the flow speed (the longer the faster). The fine
blue lines are contour lines (points of identical "height levels"). The solid gray line on the top image shows, hand-drawn, a water
retention / puddle (-> no arrows = no water flow, no drainage).
The top image shows the default system design, which develops puddles (big red arrow). The bottom image shows the same
structure after optimization, with 4 additional supporting tubes introduced. These tubes ensure that the water runs off cleanly
now. With this small change, the system is now usable long term, in any weather condition, and without any problem.
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Double Curved Tensile Membranes
Tensile membrane structures consist of a carrying skeleton, covered with canvas laid on or stretched across. The
supporting structures are usually made from steel, stainless or mild, aluminium, e-glass or carbon composites. Very
often arches or masts are included, depending on the project’s design.
The main difference between simple textile awnings and our tensile membrane structures is that these are not just
flat pieces of fabric sewn together. Membrane technology is based on the philosophy to deflect membranes in two
planes. 3D-deformation creates very strong and stable membrane shapes. There are four traditional ways to form 3D
membrane shapes:
A double shaped curve, characteristic feature of tensile membranes, offers unlimited and particularly complex shaping possibilities to attract people’s attention. It is a typical aspect of tensile membranes to imprint an artistic style
and sometimes express a personal or a ship's character. Aesthetic advantages and physical strength, as much as
lightness and modern appearance, are a part of tensile membranes as well.
The main task for our engineers when designing a sunDECK tensile structure is to use this technology and create
strong and stylish membranes - constructions of elements carrying only tension and in no case compression or bending. sunDECK tensile membranes are incomparable to simple textile awnings, as they are superior in any way:
design style shape strength longevity reliability ...
Pictures
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The most simple way to attach the membrane’s corner: stainless ring and webbing. A nice device is the tensioning hardware installed insides the stainless steel tube, completely hidden and invisible.
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A more stylish way to do this detail is a polished corner plate. This will also support the membrane better.
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Corner plate installation on board 126m KATARA in 2010 - the dimensions help understand how strong sunDECK systems are.
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Custom Engineering
Our custom engineering team is prepared to create very individual systems, exactly optimized for the individual
yacht. Our work is completely project orientated, and we have no standard procedures, products or requirements.
We do not limit ourselves to the membrane layout. For a safe, aesthetic and reliable awning structure it is required to
do an all-over design concept, which includes shaping and sizing of all components - carrying structure, deck implementation, awning shape and design, fitting / hardware layout and construction.
We do our own FEM analysis calculations - to find out what loads will occur, whether our design is safe against water
and / or ice pockets (ice is requested only sometimes, depending on the operation area of the ship), and to be sure
that the membrane will stay in perfect shape and perform strongly and quietly in all climate and weather conditions
to expect.
Project Management
Our team will carry out the full project management, and we will create a system which exactly implements the projects requirements. We will take the role of general contractor and supply the turn key product package. We will accept system responsibility. This project management happens completely in house. Installation on board will be
taken out by our team of technicians.
Pictures
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The aft end of the sunDECK system on board of OCTOPUS - a sharp angle, a high gloss mirror polished
stainless steel corner plate, a polished rigging screw, and a custom made attachment fitting for the ship
structure. SAILTEC’s contract included design and construction of the hole structure, and supply and installation of the membrane and its hardware.
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Details of a large sunDECK system on board 154m AL SAÏD, supplied in 2007. The structure includes a polished stainless steel skeleton, made from 168mm tube, about 1100 hooks to attach the outer and inner
membrane. The outer membrane is the largest single piece membrane we ever did, so far. The inner membrane consists of 12 elements of blue fabric, for decorative use. SAILTEC’s contract included design, construction and FEM load analysis for the hole structure, and supply and installation of the membranes.
This system is dome shaped like an aeroplane’s wing, and it will create about 34 tons of lift, if exposed to
100kn of wind!
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sunDECK - Membrane Characteristics
Longevity
Exposed to sunlight and permanent exposed to good and bad weather conditions, our textile fabrics prove excellent performance.
After 10 years of permanent use, the fabric still has 80% of its original brightness. Also colours are very well maintained.
Durability
Our fabric is exceptionally resistant against stretching and displays very little shrinkage. This ensures long term performance even in
tropical weather conditions and under high loads.
Dimensional Stability
Our membranes offer elongation characteristics under load very similar in warp and weft, as well as a minimum creep over time. The
balanced stability of our membranes facilitate the final assembly in the field - in most cases it is not necessary to retention the membrane regularly. Perfect performance and shaping are achieved, scarcely subject to distortion and wind load deformation.
Stylish Luminosity
Depending on the choice of translucent fabric, the interior is lit in a very natural colour. Also, our textile products offer an excellent
resistance against ultraviolet radiations and air pollution, sometimes better than traditional roofing materials. Also at night membrane
systems create very comfortable atmosphere.
Pictures
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A textile sun shade with a carrying structure made from painted aluminium.
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Detail of AL SAÏD’s sunDECK system. The peak point has a hidden integrated hydraulic push-up system to tension this large
membrane. After tensioning the membrane the cylinder is being locked off mechanically. AL SAÏD’s sunDECK system was approved for 120kn of wind, as requested by the customer. This equals 2 times force 12 on the Beaufort scale!
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This relatively simple membrane protects the stern area from sunlight. The 3D deflection design makes it extremely strong.
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Radial panel layout and wire supported structures are typical elements of lightweight tensile structures.
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sunDECK - Supporting Structures
Material and design of supporting structures vary with the character of the individual project. For commercial applications, we mostly use galvanized steel and aluminium structures. Due to appearance and visual aspects, mild steel
and aluminium are hardly ever an option for tensile structures on yachts.
Stainless Steel
For yachting applications, the choice of material mostly depends on the design and the ship’s owners or designers
wishes. For the super yacht business, one of the typical routes is to go for a structure made from mirror polished
stainless steel 1.4404.
Highest Yacht Standard & Finish Options
Our standard finish for stainless steel super yacht structures is a high gloss, mirror polished finish. For a perfect appearance, this finish requires top quality material like 1.4404 (316L). We will grind, fair and polish all welding to non
visibility. And we will provide a manual polish, which is much better in quality than machine or electro polished finishes. Sometimes customers may request brushed finish, or even fine blasted finish. No problem for us to do, but
brushed and even more so blasted finish require more care during the operation of the yacht.
Carbon Composites & Finish Options
In case of straight tubular components, we may use filament wound carbon tubes. These are affordable and offer a
good price / weight / strength relation. For individually shaped or curved structures, composite laminates are required which are made up in molds. Typically female molds result in perfect finish for visible surface areas. Finish
options are a multiple layer UV resistant polyurethane coating system, or a woven carbon top layer, deep gloss varnished.
Pictures
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X-ply carbon structure with UV protecting “deep gloss” clear coat finish. The yellow stripe is a light reflection.
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A tube joint - welded, faired and high gloss polished. This is highest yacht standard!
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Side view of a sunDECK system we made for 133m AL MIRQAB. This structure has an integrated drainage
system. The water on top of the membrane flows into the surrounding tubes and from there into the ship’s
drainage system. As you can see the shipyard has included water from the bulwark to also use this drainage.
The title page of this brochure shows another view of this system.
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Detail of KATARA’s membrane: the “tension jaw” fitting. The threads are locked with an invisible setscrew.
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postLIGHT and ledSTRIP · sunFLIP illumination.
The idea for awning systems is to be used in bright sunlight. But they are nice to
have in the dark as well, during a warm evening on deck. We supply postLIGHT,
lighting integrated into the poles, and ledSTRIP implemented into the membranes.
postLIGHT
postLIGHT is a LED light built into the sunFLIP posts. We supply them with various
LED lights, for daylight white or halogen Kelvin colour. Or, as an option, they are
also available with RGB varying colours. We supply postLIGHT equipped with a
power cord with plugs - which can be removed during the day.
ledSTRIP
ledSTRIP is an innovation that we incorporate directly into awning membranes.
Removable at any time, sealed waterproof LED strips are mounted into the awning
membrane. They provide either daylight white colour, or RGB varying colours. The
system is upgradeable and replaceable without problems - definitely an asset to
Images
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1 ledSTRIP model 1 — the LED strip is covered with Soltis,
in a Soltis awning.
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A white postLIGHT with the LED light switched on.
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ledSTRIP model 2 — with white covered LED strip,
in a Soltis awning.
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Other SAILTEC Products
We work project-oriented and provide TAILOR made system solutions for various applications on board, most outfitting systems.
Quite often we are approached for configurations with cross-system technology. Typical of SAILTEC is that we are being approached quite often for solutions to individual application requirements. It repeatedly is a motivation for us to give our customers an optimum solution. Below we present show some typical examples of our work.
sunFLIP
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sunFLIP systems are fair weather sun awning systems, made for quick set-up and take-down. The model series sunFLIP-A
with aluminium posts for architectural projects, sunFLIP-C has carbon posts, for super yachts.
sunHATCH
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sunHATCH is a large, fully automatic deck structure skylight for the owners stateroom on a large yacht. sunHTACH provides an opening of about 2.3 x 4.0, which can be modified for a new project with another customer. The system was produced as GRP construction with stainless steel drive systems.
proSCREEN
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quick-fit projection screens for the large-format video experience on deck. With CFRP support structures and tension fabric screens. Designed for quick assembly and disassembly.
proSPORT
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This court was built for the helicopter foredeck of a 147m yacht. A real impressive piece of equipment. 20m x 10m in size,
the side walls 4 m high, and even equipped with lighting - for games in the dark. Made from carbon fibre, aluminium and
plastic. The whole system is removable within 3 hours - so the foredeck may serve its main job. It is one of two helicopter
landing areas on board.
slideSHADE
(no image yet) Fully automatic sun awning systems, opening and closing load and position controlled by push-button and
SPS system.
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SAILTEC Projekt GmbH
Hasselbinnen 28
D-22869 Schenefeld
Fon 049 (0)40 822 99 40
Fax +49 (0)40 830 42 79
info@sailtec.eu
www.sailtec.eu